Method and system of making digital image transfer thermoformed objects

ABSTRACT

A method and system is provided for forming a three-dimensional image and, more particularly, for making three-dimensional digital image transfer thermoformed objects on, e.g., generic molds. The system comprises a computer infrastructure operable to receive images of a subject. display the images, stitch together the images to form a single image, adjust portions of the images or single image to compensate for deformation during thermoforming of the single image, register the single image with points on a mold, and print the single image.

FIELD OF THE INVENTION

The invention generally relates to a method and system of forming athree-dimensional image and, more particularly, to a method and systemof making three-dimensional digital image transfer thermoformed objectson, e.g., generic molds.

BACKGROUND OF THE INVENTION

For a variety of reasons it may be desirable to produce athree-dimensional likeness of a human face. And, as technology hasinvolved, so has the ability to produce such a three-dimensionallikeness. For example, several known devices use modern equipment inorder to take measurements of a human form and reproduce a solidthree-dimensional object. One such technology is the use of athree-dimensional laser and moving platform in order to take ameasurement of a head. Once the measurements are taken, they areprocessed and used to produce a three-dimensional relief of a person'shead via a laser-cutting tool. However, this practice can be ratherexpensive, time consuming and as it measures the entire 360 degreesurface of the head and reproduces a relief, not possible to make suchrelief in a timely manner.

In a more cost-effective process, a pointer-tool assembly has been usedto reproduce a person's likeness. The pointer-tool assembly comprises ahead for driving a rotary cutting tool and scanning pointerinterconnected and mounted for simultaneous displacement so that eachdisplacement of the pointer is exactly copied by the tool. This assemblyfurther includes a projection and screen unit for showing a series ofphotographic records and a work table adapted to carry a block ofmaterial from which the reproduction is to be made. Again, though, thispractice can be rather time consuming and, as such, not possible to makesuch relief in a timely manner. Also, much like the laser tool, thisprocess makes an exact reproduction of the subject, including the shapeand size of the head and facial features.

Accordingly, there exists a need in the art to overcome the deficienciesand limitations described hereinabove.

SUMMARY OF THE INVENTION

In a first aspect of the invention, a method is provided forthermoforming an image. The method includes manipulating digital imagesof a subject into a single image; printing the single image onto amedia; and thermoforming the media with the single image using a genericmold.

In another aspect of the invention, a system for deploying anapplication for thermoforming an image is provided. The system comprisesa computer infrastructure operable to: receive images of a subject;display the images; stitch together the images to form a single image;adjust portions of the images or single image to compensate fordeformation during thermoforming of the single image; register thesingle image with points on a mold; and print the single image.

In still another aspect of the invention, a computer program productcomprises a computer usable medium having readable program code embodiedin the medium. The computer program product includes at least onecomponent to provide the processes of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an illustrative environment for implementing the processesin accordance with the invention;

FIG. 2 show process steps of making a three-dimensional digital image inaccordance with the invention;

FIG. 3 shows a flow diagram implementing processes in accordance withaspects of the invention; and

FIGS. 4-5 show various implementations of the invention.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The invention generally relates to a method and system of forming athree-dimensional image and, more particularly, to a method and systemof making three-dimensional digital image transfer thermoformed objectsusing generic molds. By implementing the system and method of theinvention, it is now possible to efficiently manufacture a miniaturescale photo-realistic three-dimensional reproduction of a subject. Inaccordance with the invention, the photo-realistic three-dimensionalreproduction of a subject can be made in the presence of the subject, orwith digital photographs provided via the Internet or other medium.Advantageously, the method of the invention takes advantage of variousexisting technologies that have only recently been made practical by theadvent of low priced dye sublimation printing and advanced photographicmanipulation software (manipulation tool).

In embodiments, different technologies such as, for example, digitalphotography technology, digital photographic imaging software, imagemodification software, image transfer technology and thermoplasticvacuum forming are implemented to make the three-dimensionalthermoformed object. In embodiments, the image transfer technology isdye sublimation printing processes. As should be understood by those ofskill in the art, dye sublimation printing employs a printing processthat uses heat to transfer dye to a medium such as a plastic card. Theimage modification or manipulation software can be any off the shelfmanipulation software that allows for bitmap and image manipulation. Inone preferred application, the image modification or manipulationsoftware (manipulation tool), e.g., PhotoShop® sold by Adobe® SystemsIncorporated, allows for stitching together images, compressing portionsof the image and other manipulations, as modified and contemplatedherein.

The method and system of the invention can preferably be implemented tomanufacture three-dimensional photo Identification badges,three-dimensional luggage identification, key chains, action figures,and any other applications. Many of these applications lend themselvesto entertainment venues such as, for example, fairs, carnivals, themepark, and sporting event venues. However, applications go beyond that ofthe entertainment market, with applications in the security andadvertisement fields. For example, existing identification badges can beimproved by use of the three-dimensional images, in addition to othersecurity features. As to advertisement, such use can extend intoproviding a display of a consumer proximate to a retail item, enticingthe consumer to purchase such item.

FIG. 1 shows an illustrative environment 10 for managing the processesin accordance with the invention. To this extent, the environment 10includes a computer infrastructure 12 that can perform the processesdescribed herein. In particular, the computer infrastructure 12 includesa computing device 14 that is operable to manipulate a digital imagesuch that it can be printed on a laminate for forming into athree-dimensional likeness of the subject. More specifically, thecomputing device 14 includes a manipulation tool 16 operable to receivea frontal image and side images of the subject, stitch together thedifferent images and make adjustments, e.g., compress, to the images inorder to print such image on a laminate. The compression is provided tothe side images in order compensate for material deformation duringthermoforming. That is, as adjustments are made in the two side images,the three-dimensional image can be formed in an anatomically correctmanner. The amount of image compression required could be calculatedusing existing technology such that the calculated compression isrepeatable; however, in embodiments, side images of the subject can becompressed manually. In embodiments, the compression is about 50% to 60%in order to compensate for material deformation.

The computing device 14 includes a processor 20, a memory 22A, aninput/output (I/O) interface 24, and a bus 26. Further, the computingdevice 14 is in communication with an external I/O device/resource 28and a storage system 22B. In embodiments, the manipulation tool 16 isstored in the memory 22A, as is shapes and registration or alignmentmarks of generic molds as discussed in more detail below. The bus 26provides a communications link between each of the components in thecomputing device 14. The I/O device 28 can comprise any device thatenables an individual to interact with the computing device 14 or anydevice that enables the computing device 14 to communicate with one ormore other computing devices using any type of communications link. Forexample, the I/O device 28 can be a digital camera.

The processor 20 executes computer program, which is stored in memory22A and/or storage system 22B. The computer program code can beassociated with and running of the manipulation tool 16. While executingcomputer program code, the processor 20 can read and/or write datato/from memory 22A, storage system 22B, and/or I/O interface 24. Thecomputer program code includes the processes of the invention asdiscussed herein.

The computing device 14 can comprise any general purpose computingarticle of manufacture capable of executing computer program codeinstalled thereon (e.g., a personal computer, server, handheld device,etc.). However, it is understood that the computing device 14 is onlyrepresentative of various possible equivalent-computing devices that mayperform the processes described herein. To this extent, in embodiments,the functionality provided by computing device 14 can be implemented bya computing article of manufacture that includes any combination ofgeneral and/or specific purpose hardware and/or computer program code.In each embodiment, the program code and hardware can be created usingstandard programming and engineering techniques, respectively.

Similarly, the computer infrastructure 12 is only illustrative ofvarious types of computer infrastructures for implementing theinvention. For example, in embodiments, the computer infrastructure 12comprises two or more computing devices (e.g., a Client/Server) thatcommunicate over any type of communications link, such as a network, ashared memory, or the like, to perform the process described herein. Thecommunications link can comprise any combination of wired and/orwireless links; any combination of one or more types of networks (e.g.,the Internet, a wide area network, a local area network, a virtualprivate network, etc.); and/or utilize any combination of transmissiontechniques and protocols.

A service provider can create, maintain, deploy and support theinfrastructure such as that described in FIG. 1. The service provider,such as a Solution Integrator, advertiser, etc., could offer to performthe processes described herein for payment from the customer(s) under asubscription and/or fee agreement and/or the service provider canreceive payment from the sale of advertising content to one or morethird parties.

FIG. 2 shows process steps of making a three-dimensional digital imagetransfer in accordance with the invention. In particular, FIG. 2 showsthe manipulation tool 16 implemented in the environment of FIG. 1, forexample. A photograph of a subject, represented in pane “A”, is firstuploaded into the software manipulation tool 16. Pane “A” is onlyrepresentative of the frontal view of the subject; however, it should beunderstood that two side views are also uploaded into the manipulationtool 16. In embodiments, the side views are a left view and a right viewof the subject, taken at an approximate 30 degree angle from the frontalview. Pane “B” is representative of the stitching process, e.g.,stitching of the frontal view with the two side views. Pane “C” isrepresentative of the compression process. More specifically, pane “C”shows graphically the compression of the side views in order tocompensate for material deformation during thermoforming. It should beunderstood that the stitching and compression steps could beinterchangeable such that the compression can be performed prior to thestitching and vice versa.

In one embodiment, the manipulation process also includes an imageregistration process such that, for example, the eyes, ears, nose andmouth of the subject will align with the face mold used in thethermoforming process. The registration can include marks at theappropriate positions in the image, e.g., mouth, ears, nose, etc.,represented as reference numeral 200. The registration can be performedmanually or by the manipulation tool 16, as discussed below.

In further embodiments, the manipulation tool 16 includes a predefinedmatrix of different generic mold faces. The matrix can be uploaded tothe manipulation tool 16 with the digital images or stored in a storage.The matrix represents the generic face mold to be used in thethermoforming step and includes registration marks for orientingfeatures of the images (i.e. nose, ear, eyes, mouth, etc.). In thisimplementation, the manipulation tool 16 is configured to automaticallyalign the registration marks of a selected generic mold with knownfeatures of the subject face. (This can be represented as pane “C”, forexample.) By automatically aligning the registration marks with featuresof the image (or vice versa), the manipulation tool 16 alsoautomatically and accurately compresses the side images as theregistration marks of the generic mold and features of the side images(e.g., ears) are used as a template for the compression. That is, as theears, for example, are aligned, a proper compression will automaticallybe realized.

Once the images are stitched together and compressed, they are printedto a laminate using, for example, dye sublimation printing. Inembodiments, the image is printed onto a PVC-type media. In onepreferred embodiment, the image is printed onto 10 mil PVC plasticsheets. The dye sublimation printer should preferably use a lineartransport as this type of mechanism does not bend or roll the media. Inone embodiment, the printing process can include the image registrationprocess such that, for example, the eyes, ears, nose and mouth of thesubject will align with the face mold used in the thermoforming process.

During the manipulation process or after the printing process, abest-fit match is made between the printed image and the face mold. Inembodiments, the best-fit match is made between the manipulated imageand one of several generic molds. In one preferred embodiment, thebest-fit determination may be made during the manipulation process,where a generic mold matrix is already uploaded and/or stored in themanipulation tool 16 or other storage, e.g., storage 22B. It isinteresting to note that the image of the subject seems to play a muchlarger role in visual perception than does the subtle differences in theshape of the face mold. As such, it has been found that the physicalshape of the face mold contributes less to the overall realism of thesubject compared of the actual visual image of the subject. With thisobservation, a generic mold has been found to be sufficient for purposesof implementing the invention; although customized molds can also beused with the invention.

The generic molds, in implementations, are representative of common faceshapes. For example, the generic molds can be the following common faceshapes: long, oval, square, round, youthful, geriatric, etc. Inaddition, the generic molds can be customized to include certainidentifying features such as, for example, long nose, full lips, largeeyes, etc. The generic molds, e.g., shapes and alignment marks forregistration, can be stored in the environment of FIG. 1 such that theregistration of the manipulated image and the mold can be automated, ormanually manipulated. Those of skill in the art should understand thatthe above examples are illustrative non-limiting examples of manydifferent face types and features. As such, the invention should not belimited to such face types and features.

Once the best-fit match is made and printing has been accomplished, theprinted laminate can be molded in a conventional manner using knownthermoplastic vacuum forming machines. The three-dimensional image,e.g., face, once formed, is trimmed using a die cutting tool.

FIG. 3 shows a flow diagram implementing processes in accordance withaspects of the invention. FIG. 3 equally represents a high-level blockdiagram of the invention. Additionally, the invention can take the formof an entirely hardware embodiment, an entirely software embodiment oran embodiment containing both hardware and software elements. In anembodiment, the invention is implemented in software, which includes butis not limited to firmware, resident software, microcode, etc.Furthermore, the invention can take the form of a computer programproduct accessible from a computer-usable or computer-readable mediumproviding program code for use by or in connection with a computer orany instruction execution system. The software and/or computer programproduct can be implemented in the environment of FIG. 1. For thepurposes of this description, a computer-usable or computer readablemedium can be any apparatus that can contain, store, communicate,propagate, or transport the program for use by or in connection with theinstruction execution system, apparatus, or device. The medium can be anelectronic, magnetic, optical, electromagnetic, infrared, orsemiconductor system (or apparatus or device) or a propagation medium.Examples of a computer-readable medium include a semiconductor or solidstate memory, magnetic tape, a removable computer diskette, a randomaccess memory (RAM), a read-only memory (ROM), a rigid magnetic disk andan optical disk. Current examples of optical disks include compactdisk-read only memory (CD-ROM), compact disk-read/write (CD-R/W) andDVD.

Referring to FIG. 3, at step 300, a frontal view and two side images areimported or uploaded into the manipulation tool. At step 305, the imagesare stitched together and compressed according to the geometry of themold. At step 310, the manipulated image is registered with pointsassociated with the mold. In embodiments, the registration may beprovided using a mold matrix, stored in the manipulation tool or otherstorage in accordance with the invention. At step 315, the manipulatedimage is printed using, for example, dye sublimation. At step 320, theprinted image is thermoformed and trimmed using a die cutting tool.

FIGS. 4-5 show various implementations of the invention. FIG. 4 showsthe invention being implemented in an identification badge 400. As notedabove, the three-dimensional image of the subject on an identificationbadge can be used to improve security measures. The identification badge400 can include other security features such as, for example, name ofsubject, identification number, security clearance, etc. FIG. 5 showsthe invention implemented for entertainment or advertisement purposes.That is, the mold is superimposed onto a body clothed with garment forpurchase in a retail environment.

Additional realism could be attained by transferring detailed physicalcharacteristics (i.e. nose shape, eye position, cleft chin, etc.) to themold. A “pin sculpture” device could be used to capture the details ofthe facial features. These features could then be translated to scaleand then used as the mold for the thermoformed object.

While the invention has been described in terms of embodiments, thoseskilled in the art will recognize that the invention can be practicedwith modifications and in the spirit and scope of the appended claims.

What is claimed is:
 1. A computer program product comprising a computerusable storage medium having readable program code embodied in thestorage medium, the computer program product includes at least onecomponent operable to: receive images of a subject; stitch together theimages to form a single image; compress portions of the single image tocompensate for deformation during thermoforming of the single image;register the single image on a mold; store a matrix of the mold; andprint the registered single image by a dye sublimation printer.
 2. Thecomputer program product of claim 1, wherein the matrix includesregistration marks for orienting features of the single image.
 3. Thecomputer program product of claim 1, wherein the mold includescustomized features.
 4. The computer program product of claim 3, whereinthe customized features are captured by a pin sculpture device.
 5. Thecomputer program product of claim 1, wherein the portions of the singleimage are compressed to about 50% to 60%.
 6. The computer programproduct of claim 1, wherein the images comprise a frontal view and sideviews.
 7. The computer program product of claim 6, wherein the sideviews are taken at about a 30 degree angle from the frontal view.
 8. Thecomputer program product of claim 1, further comprising the at least onecomponent operable to best-fit match the single image and the mold. 9.The computer program product of claim 1, wherein the dye sublimationprinter is a linear transport type.
 10. The computer program product ofclaim 1, wherein the single image is printed onto Polyvinyl chloride(PVC) plastic sheets.
 11. A system for thermoforming an image,comprising: a computer infrastructure being operable to: receive imagesof a subject; stitch together the images to form a single image; adjustportions of the single image to compensate for deformation duringthermoforming of the single image; register features of the single imageon a mold; store a matrix of the mold; and print the registered singleimage by a dye sublimation printer.
 12. The system of claim 11, whereinthe computer infrastructure is configurable to adjust the portions ofthe single image by compression.
 13. The system of claim 12, wherein thecompression comprises compressing the portions of the single image toabout 50% to 60%.
 14. The system of claim 11, wherein the dyesublimation printer is a linear transport type.
 15. The system of claim11, wherein the mold includes customized features.
 16. A method forthermoforming an image, comprising: receiving images of a subject;stitching the images together to form a single image; thermoforming thesingle image; compressing the single image to compensate for deformationfrom the thermoforming; registering features of the single image on amold; storing a matrix of the mold; and printing the registered singleimage by a dye sublimation printer.
 17. The method of claim 16, whereinthe images comprise a frontal view and side views.
 18. The method ofclaim 17, wherein the stitching comprises stitching together the frontalview and the side views.
 19. The method of claim 17, wherein the sideviews are taken at about a 30 degree angle from the frontal view. 20.The method of claim 16, wherein the compressing comprises compressingside portions of the single image to about 50% to 60%.